Downloaded 67 times
Uploaded byShruti Railkar
Sustainability case tata power
This document provides a case study on Tata Power's efforts to increase the sustainable use of bottom ash, a byproduct of coal combustion. It details the quality circle team's application of the PDCA (Plan-Do-Check-Act) process to address the problem of disposing 625 metric tons of bottom ash per month. Through root cause analysis, trials, and regular implementation, the team developed a solution to incorporate bottom ash into bricks, reducing monthly disposal to 300 metric tons. Tangible benefits included savings of over Rs. 4 lakhs in transportation costs and Rs. 18 lakhs in natural sand costs. Future plans aim to further reduce disposal and deploy the approach across Tata Power.
More Related Content
Similar to Sustainability case tata power
Sustainability case tata power
- 1. Bombay Chapter of Commerce SustainabilityCase Study MET Institute of Management ,Mumbai Team: Blaze Shruti Railkar btshruti@gmail.com +91 9969004297 Kunal Thakur kunal68@gmail.com +91 8879118457
- 2. First time BottomAsh used in Bricks by QC Team TATA Power Philanthropy without scale and sustainability is like any other bad business that will simply wither and die on the vine. -Naveen Jain 2
- 3. Our Approach Company Analysis PDCACycle Benefits Future Plans 3
- 4.
- 5.
- 6.
- 7. • To bethe most admired and responsible Integrated Power Company with international footprint, delivering sustainable value to all stakeholder. VISION • We will become the most admired and responsible Power Company delivering sustainable value by: • Operating our assets at benchmark levels • Executing projects safely, with predictable benchmark quality, cost and time • Growing the Tata Power businesses, be it across the value chain or across geographies, and also in allied or new businesses • Driving Organizational Transformation that will make us have the conviction and capabilities to deliver on our strategic intent • Achieving our sustainability intent of ‘Leadership with Care’, by having leading and best practices on Care for the Environment, Care for the Community, Care for the Customers and Shareholders, and Care for the People MISSION Company PDCA Cycle Benefits Future Plan 7
- 8. TOTAL GENERATION CAPACITY6999MW 8 Company PDCA Cycle Benefits Future Plans
- 9. QUALITY CIRCLE TEAM QC TEAM UWGaikwad LEADER Priyanko Majumdar Rambhau Rekhate AB Suryavanshi Prashant Rane FACILITATOR 9 Company PDCA Cycle Benefits Future Plans
- 10. PROBLEM SOLVING CONTENTS CompanyPDCA Cycle Benefits Future plans 10
- 11. STEP 1: Identificationof problem BRAINSTORMING TOTAL NO OF PROBLEMS IDENTIFIED=60* *List of problems provided in appendix Company PDCA Cycle Benefits Future plans 11
- 12. STEP 2: Selectionof Problem Company PDCA Cycle Benefits Future plans 12
- 13. Selection Of Problem Theproblems were categorized in A,B,C categories (A,B,C analysis) A category-Which can be solved by QC circle B category-Which can be solved by other department C category-problems which require management approval A 68% B 17% C 15% Percentage Category A = 41 Category B = 10 Category C = 9 Company PDCA Cycle Benefits Future plans 13
- 14. Selection Of Problem QCTEAM DECIDED -CATEGORY A STRATIFICATION A CATEGORY Environment : 4 Safety/Health : 13 Cost:6Moral:6 Quality :12 Selection Of theme Sustainability/environment was selected since plant is located in heart of Mumbai city which is densely populated • Slide 2 of 59 Directly linked to MISSION statement Environment Company PDCA Cycle Watch Industry Cost analysis 14
- 15. STEP 3: DEFININGTHE PROBLEM Company PDCA Cycle Benefits Future plans 15
- 16. Defining The Problem Reason •In Trombay Thermal Power Station, Coal is used as major fuel for Power generation . • Ash is a byproduct Type • Fly Ash-which is total burnt coal and which resale to Cement construction company • Bottom Ash –No resale value. Therefore we have to dispose it off. % Content • The total % of Ash is divided in to two parts i.e. around 80% Fly Ash & 20% Bottom Ash Requireme nt • Coal requirement for Trombay is around 9000 MT per day. Company PDCA Cycle Watch Industry Marketing strategy Cost analysisCompany PDCA Cycle Benefits Future Plans 16
- 17. Defining The Problem Ash •They are using good quality Imported Indonesian coal, it contains around 1-2% of ash content. Content • Bottom Ash Generated: 7500 MT/yr. (625 MT/month) • Fly Ash generates: 37500 MT/year. Future • After conversion of U#6 from Oil to coal, Bottom ash generation may increase by 5000 MT/year Company PDCA Cycle Benefits Future plans 17
- 18. Defining The Problem CompanyPDCA Cycle Watch Industry Marketing strategy Cost analysis 18
- 19. Defining The Problem CompanyPDCA Cycle Benefits Future plans 19
- 20. Environment pollution Huge amountdisposable bottom ash 625 T/month(65trucks) Disposable at the distance of 30KM People have to work at night since transportation is at night. Expenses Incurred on transportation 3,00,000/- month Lack of space for storage Bottom ash. Affect Green Manufacturing Index(GMI)4 Defining The Problem 20 Company PDCA Cycle Benefits Future plans
- 21. As per CentralElectricity Authority of India ‟Per Megawatt(MW) area calculation required for imported coal is:0.47Acre/MW But our plant is running/installed at the ratio of :0.27Acre/MW (Situated in Mumbai (Metro city) Already they are running their plant with lesser area. Cleanness/healthiness or up keeping of the plant area got affected due continues storage of the Bottom within plant area. Also as per MOEF (Ministry Of Environment & Forest ) notification we can store the Bottom Ash(solid waste) upto:3Months only Defining The Problem Company PDCA Cycle Watch Industry Marketing strategy Cost analysis 2121
- 22. Defining The Problem ToImprove: •Green Manufacturing Index (GMI) . (Directly linked to Companies “MISSION”) To reduce Environment pollution Storage & Transportation problem Expenses incurred for disposable of bottom ash Working at night shift Company PDCA Cycle Benefits Future plans 22
- 23. Defining Of Problem(Goal setting) Disposing at present (MT/Month) Planned disposal (MT/Month) Bottom ash in MT 625 300 0 100 200 300 400 500 600 700 BottomashInMT Bottom ash in MT To reduce disposable of bottom ash from 625MT/Month to 300MT/Month Company PDCA Cycle Benefits Future plans 23
- 24. STEP 4: Analysisof Problem Company PDCA Cycle Benefits Future plans 24
- 25. ANALYSIS OF PROBLEM5W & 1H TOOL What? •625MT/month-transportation •Around Rs.3.2 Lakhs per month expenses Where? •Plant situated at trombay in Mumbai •Transported outside the plant area as permitted by MPCB(Maharashtra pollution control board When? •Ash generated 365 days of the year •Transportation in late hours Who ? •Problem is irrespective of person –Process related How? •Transported at late night by dumpers . •Spillage •Environmental pollution Summery of SAP report Year Bottom ash qty in MT/year Amount spent for disposal in lakhs 2007-08 7000 35 2008-09 8600 44 2009-10 7500 40.5 2010-11 7350 37.5 Company PDCA Cycle Benefits Future plans 25
- 26. Step 5: Identificationof causes 26 Company PDCA Cycle Benefits Future plans
- 27. Identification Of Causes EnvironmentPerson System Material 27 Company PDCA Cycle Benefits Future plans
- 28. Identification Of RootCauses By Why-Why Analysis Ash Content in 100% pure coal is not available Available from natural mines Why ? Why ? Coal Economically & easily available than Oil & Gas Why ? Transportation By Road Disposal yard is 30KM away from plant Only MPCB approved dumping yard Why ? Why ? Company PDCA Cycle Benefits Future Plans 28
- 29. Identification Of RootCauses By Why-Why Analysis Space constraint More generation in small space Generation has been increased from 180MW to1580MW Need for power Industrial growth Dumping Environmental Constraint Mumbai (Metro city) Today TATA power have dumping permission but they are not sure about tomorrow Why ? Why ? Why ? Why ? Why ? Why ? Why ? Company PDCA Cycle Benefits Future plans 29
- 30. STEP 6: DATAANALYSIS 30 Company PDCA Cycle Benefits Future plans
- 31. Data Analysis Total amountspent in last 4 years- 157 lakh Avg amt spent till date-39.25 lakh/yr Total Bottom Ash disposed- 30450MT(FOR LAST 4 YRS) Avg bottom ash disposed-7612 MT/yr SAP REPORT Company PDCA Cycle Benefits Future plans 31
- 32. Data Analysis Disposal areais far away from plant 30 km • Bottom ash needs to be disposed at MPCB approved are Ash Content in a Coal • Indian coal has 30-40% ash content Company PDCA Cycle Benefits Future plans 32
- 33. STEP 7: DEVELOPINGSOLUTION 33
- 34. Some of thesolution listed down Sr No Description Statement Remark 1 Use of other fuels like gas/oil instead of coal Coal is economical than other fuel Rejected 2 Transfer the plant at a remote location Very costly. Not possible at this moment Rejected 3 Use of 100% pure coal Got the coal from natural mines. 100% pure coal not available Rejected Company PDCA Cycle Watch Industry Marketing strategy Cost analysis 34
- 35. Developing Solution Possible usageof bottom ash Non structuring work like PCC, Plastering Leveling Bed for Paver blocks Molding of bricks Paver blocks Structural/Masonary work Company PDCA Cycle Watch Industry Marketing strategy Cost analysis Company PDCA Cycle Benefits Future plans 35
- 36. STEP 8: TRIALIMPLEMENTATION 36 Company PDCA Cycle Benefits Future plans
- 37. Developing solution Sr. NoSolution Statement Remark 1 PCC and plastering work We can replace bottom ash instead of sand in the PCC & plaster Selected 2 Bottom Ash Bricks As per result we can use it Bricks Selected 3 Leveling bed for paver block We can use it for leveling of paver block Selected 4 For masonry work Ash can be used instead of sand Selected Company PDCA Cycle Benefits Future plans 37
- 38. TRIAL IMPLEMENTATAION Company PDCACycle Benefits Future Plans 38
- 39. TRAIL IMPLEMENTATAION 39 Company PDCACycle Benefits Future plans
- 40. Trial Implementation Sample No Ratio (by volume) ProportionWeight (KG) Strength Cement Bottom Ash % (Kg/brick) Fly Ash Stone Dust MPA (N/mm2) 1 1:4:6 7.5% 42.50%(1.35) 50% Nill 4 7.52 2 1:5:4 8.6% 51%(2.04) 40.4% Nil 4 15.64 3 1:6:3 8.6% 61.13(2.44) 30.29 % Nil 4 11.70 4 1:8:3 7.12% 67.71%(2.84) 25.16 % Nil 4.2 11.4 5 1:8:2 7.18% 73.91%(2.83) 18.31 % Nil 3.8 15.67 6 1:10:3 6.1% 72.4%(2.78) 21.5% Nil 3.84 6.24 Company PDCA Cycle Benefits Future Plan
- 41. Comparison Between ClayBrick & Bottom Ash Brick Sr No Property Clay Brick Bottom Ash Brick Remark 1 Compressive strength 5-6MPA 15-16MPA 3 time more 2 Density 1800-1900 Kg/cm2 1900-2000 Kg/cm2 Acceptable 3 Water Absorption 10-20% 10-20% Ok Company PDCA Cycle Benefits Future Plan
- 42. STEP 9:REGULAR IMPLEMENTATION CompanyPDCA Cycle Benefits Future plans 42
- 43. REGULAR IMPLEMENTATION • Duringtrial implementation it was confirmed that we will continue with the proportion 1:8:2 having an un expected strength value of 15.67MPA. • Decided, we will implement the trial proportion 1:8:2 on regular basis. • Consumption of Bottom Ash per Brick is 2.83KG. • 250 bricks per Day. • We have increased our brick molding from 250 bricks/day to 350 Bricks/day. • Utilizing 990KG Bottom Ash daily for molding of 350 Bricks. • Bottom Ash Consumed for PCC work per meter cube (M3) = 765KG • (APPENDIX-84) Company PDCA Cycle Benefits Future Plans 43
- 44. Regular Implementation Bottom AshBrick Company PDCA Cycle Watch Industry Marketing strategy Cost analysis 44
- 45. TROMBAY PLANT AREA CompanyPDCA Cycle Benefits Future plans 45
- 46. TANGIBLE BENEFITS Cost BenefitAnalysis: • After installation of Pilot Brick plant Bottom Ash is used in making of Bricks, PCC (Plain cement Concrete), Plaster & masonry work and curbing work for all new Gardens developed - total Bottom Ash Consumed within 6 and half month = 875 MT (Metric Ton) • Saved the transportation cost for 875 MT • Transportation and Disposal cost of Bottom Ash per Ton is Rs. 510. • Direct saving in the transportation cost of Bottom Ash = 875 X 510 =4,46,250/- • As we had replaced the natural sand by using Bottom ash, we saved the cost of procuring Natural Sand for 875 Metric Ton. • Cost of 1 Ton sand = 2100/- (if easily available, but now a day‟s natural sand is not easily available) • Cost of 875 Metric Ton Sand saved = 875 X 2100 = 18,37,500/-Saving due to utilization of Bottom Ash instead of Sand in Bricks and civil work i.e. if we had purchased the sand for above work we would have to spend around: Rs. 18,37500/ Company PDCA Cycle Benefits Future plans 46
- 47. INANGIBLE BENEFITS Care ofEnvironment &contribution to wards sustainability: • As in this project we are able to reduce the storage and disposal problem of Bottom Ash. • Reduction of pollution in transport of Bottom Ash • Reduction in fuel cost and saving precious resources (diesel) for the transport of Bottom Ash , Bricks & natural sand. • Reduction in carbon foot print of the company. • Fatigue of workers reduced in the transportation of Bottom Ash , Natural sand and Bricks. • Reduction in mining of natural sand • Reduce, Reuse and Recycle .Contribution to wards Greenolution . Reusing the Bottom Ash in Civil work. • Team work Experience As a team we worked together to achieve our goal. 47 48 Company Pen Industry Benefits Future plans
- 48.
- 49. Future Plan To achieveour goal of reducing disposal of Bottom Ash from 625 MT/months to 300MT/month & zero disposal by 2020 following are the future plans: •Taking Clearance for the Radioactivity test to use the Bottom Ash Bricks for Structural and in- house. work : Samples submitted on 12/10/12 to BRIT office (Department of Atomic Energy, Radio analytical laboratory , Govt. of India, Mumbai ) for testing . Waiting for the results. •Installation of Large capacity Brick plant having the capacity around 2000 to 3000 numbers of bricks per day. •Utilization of Bottom Ash for the structural use. •Making of Paver blocks by using Bottom Ash. •After successful implementation of above plans we can reduce our Bottom Ash disposal to 300MT/months within next two years. •Horizontal Deployment all over the TATA POWER.(Already Started) •100% Utilization by 2020. •Will be one of the future economical and eco-friendly construction materials Company Pen Industry Benefits Future Plan 49
- 50.
- 51.
- 52.
- 53.
- 54.
- 55. Selection of Problem-RATINGMETHOD 0 20 40 60 Problem 3 Problem 5 Problem 17 Problem 34 Rating Rating 55
- 56.